Provide consulting services on:• casting metallurgy/foundry engineering• quality control• process improvement• product development

Spearheaded and executed various material, component, and process development initiatives to support new technology and product introduction for various GE businesses to reduce costs, improve productivity, and grow market share.Key Contributions:• Developed new methods for diffusion bonding TiAl to dissimilar materials to enable IGT latter stage bucket fabrication (one US IP filing and two pending for 2015 filing).• Developed the foundry process and identified a casting vendor to make the coil support structure for a new GE Healthcare MRI system; allowed the MRI system manufacturing process to meet its 2015 production cost and launch targets (five US and PCT filings).• Invented proprietary SiC shell system and “Ultra High Gradient” process and applied them to making large scale Alnico DS/SX castings for electric motor applications (two US IP filings).• Developed a non-evasive method for removal of additively manufactured tungsten components from steel substrate after DMLM processing to eliminate costly post-DMLM operations (one IP filing rated for 2015).• Developed proprietary coating solutions and a loose sand lost foam steel casting process for GEP&W CrMoV steel lost foam casting NTI release (five US and foreign country IP filings).• Supported counter-gravity casting of turbine structure component for GE Aviation PP20 engine test and received the program “Casting Expertise” Award.• Invented multiple methods and molten metal delivery systems to enable GE Aviation gas turbine first stage nozzle recast repair for cost reduction (Five US and PCT filings).

Analyzed and identified market niche to develop new materials and processing technology solutions. Sought out and applied for research funding and development contracts for material invention and technology development. Led technology developments to meet the customer expectations with timely deliverables and effective budget controls and reported to the customers, executives, and shareholders periodically.Key Contributions:• Prepared and proposed technical proposals and business plans, applied for and won government funding totaling $600,000 through two phases of the NSF SBIR Program for new technology development (PCT filing in 2010): (“Bendable ceramic membrane commercialization (2010)” and “Bendable ceramic membranes (2009)”. • Designed, built, tested, and released a PIM pilot station to a client for making metal matrix SiC substrate for power electronics IGBT modules (2009); the company now is selling the products to global power electronics customers.

Proposed and or executed more than 30 production support and process improvement projects for GM and Hitchiner to reduce costs, improve productivities, and advance casting process capabilities.Key Contributions:• Discovered a defect formation mechanism in lost foam aluminum casting, developed solutions and applied them to GM production lines with significant success, won 2005 AFS Howard Taylor Award and won a US patent award.• Analyzed high-occurrence rate defect data for high volume casting parts to identify the root causes, and developed a solution that resulted in annual savings of $1,000,000 across the corporation (Hitchiner Ferrous Division).• Investigated excessive shell material disposal issues induced by binder gelling, modified the binder quality control SPI, and reduced unnecessary disposal and handling cost by $400,000 annually (Hitchiner Gas Turbine Division).• Identified the root cause of melt preparation issues for Hitchiner’s Mexico Division and modified the melt preparation SPI, which reduced casting scrap rate by ~30%, equivalent to ~$300,000 of production cost savings.

Accepted and received process training on Hitchiner processes; led a corporate process auditing for scrap reduction.